Folks, I gave up on the CF cards I had and went the SSD route. Ended up getting four Imation 16GB MOBI 3000 SATA SSD drives ( http://www.imation.com/en/Imation-Products/Solid-State-Drives/PRO-and-MOBI-Series/Solid-State-Drive-MOBI-3000/). They work great, are completely silent, have more storage than my original CF's and are designed to last a lot longer than an average CF. They also have no appreciable heat signature.
I've loaded Debian 5.0 on two systems, and pfsense on the other two, and everything works perfectly. Thanks for everyone's suggestions. Pic of the final install here: http://www.flickr.com/photos/spmitchell/3294043561/sizes/m/
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